OPERATIONS/PARTS MANUAL FOR PATTERSON'S … Winch... · 6 3. OPERATION OF WINCH 3.3. The electric brake is a disc type, normally set by mechanical spring pressure. It is released

W. W. Patterson Company3 Riversea Road

Pittsburgh, PA 15233Phone: 800-322-2018FAX: 412-322-2785

OPERATIONS/PARTS MANUALFOR

PATTERSON'SMODEL # WWP65E-10-14

ELECTRIC WINCH.

Please fill in the following blanks and then keep this manual in a safe and convenient location.When calling with either questions or replacement part needs, always refer to the Winch Model,Part Number and Serial Number.

WINCH PART #: 5260-G WINCH SERIAL #: ________________

MOTOR MFG.: _____________________ MOTOR SERIAL #: __________________

BRAKE SERIAL #: _________________ DATE PURCHASED: ________________

DISTRIBUTOR INFORMATION

NAME: _________________________________________________________________

ADDRESS: ______________________________________________________________

CITY: _____________________________ STATE: ___________ ZIP: ____________

PHONE: ___________________________ FAX: _____________________________

DOC #5260-G

IMPORTANT!Prior to installing and operating the winch, please read this manualthoroughly and carefully. Keep this manual and all other instructionsaccessible at all times.

Although this manual will help you become familiarized with the operatingprocedures for the winch, it is by no means a substitute for proper training andthe safe use of winches, barge rigging and other marine equipment. Becauseowners and operators are solely responsible for determining whether a particularusage is acceptable, only individuals trained in the proper use of winches, bargerigging and other marine equipment should operate winches.

The typical operational environment of winches includes very high forces, andthe potential hazards associated with these forces should not be underestimated.Improper installation or misuse of the winch may result in injury to persons orcause equipment failure or damage.

ALWAYS OBSERVE THESE BASIC SAFETYPRECAUTIONS:

• To reduce potential of electrical shock or other injury, turn off and lock out or tagout power source before initiating any maintenance or repairs.

• Keep all fingers, loose clothing and any foreign objects away from winch while inoperation.

• During operation of the winch, always remain to the side of the winch, slightlybehind the gear motor.

• Never operate the winch from the front or when bystanders are in front of it.• Operators and bystanders should stay clear of any load and the wire rope while the

winch is operating.• Under no circumstances, should any winch be used to move, raise or lower a

person(s) or equipment.• Do not operate the winch unless you have a firm stance on a non-slippery surface.• Do not apply tension to the winch unless there are at least four complete wraps of rope

on the drum.• Inspect the winch carefully at least once a month for worn gears and pawls,

cracked welds, and other damaged parts. If any worn, cracked or damaged partsare found, stop use immediately and remove the winch from service until all

appropriate repairs are completely made.

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1. INSTALLATION

THERMOSTATLEADS

ELECTRA-GEARMOTORS ONLY

WARNING! WINCHES SHOULD ONLY BE LIFTEDBY THE LIFTING EYES ON EACH SIDE OF THEWINCH. NEVER LIFT THE WINCH BY THEGEARMOTOR OR DAMAGE WILL OCCUR !

1.1. All winches must be installed on flat, rigid and non-slippery surfaces. Deck and structure must be strongenough to withstand the weight and holding capacity of thewinch, and the forces likely to occur during operation.

1.2. Place the winch in the mounting area, in line with thedirection of cable pull. Check to make sure there is enoughclearance and Fleet Angle Distance for proper operation.(Refer to Diagram on Page 8.)

1.3. Weld to deck along the complete length of both footmounts. Use seal welding to protect the weld againstcorrosion. Remember, the weld has to be strong enoughto withstand loads equal to, at least, the Ultimate ShockLoad Capacity of the winch.

WARNING! ONLY A QUALIFIED ELECTRICIANSHOULD WIRE CONTROL BOX AND REMOTE STA-TION OF A WINCH. W. W. PATTERSON COMPANY ISNOT LIABLE FOR DAMAGE CAUSED BY UNAUTHO-RIZED OR UNQUALIFIED PERSONNEL ATTEMPINGTO CONNECT A WINCH TO A POWER SOURCE.

1.4. All winches have been factory wired to 230V unless

THERMOSTATLEADS

ELECTRA-GEARS ONLY

otherwise specified at time of original purchase. AllElectra-Gear motors are equipped with a protective ther-mostat and all Patterson control boxes are equipped witha thermal switch. All winches have been factory testedprior to shipment to insure proper operation. Assuming thecontrol box and remote station have been properly in-stalled and wired, no further wiring is required except toconnect the winch to the control box.

1.5. Open the conduit box located on the motor. The brakeand motor have been prewired at the factory and thenumbered wires have been grouped according to thevoltage of the motor. All Electra-Gear motors, in additionto these bundles, will have two leads from the thermostat.

WARNING! DO NOT SEPERATE INDIVIDUAL WIRESFROM A BUNDLE. EACH WINCH HAS BEEN FAC-TORY WIRED TO 230V UNLESS OTHERWISE SPECI-FIED AT TIME OF ORIGINAL PURCHASE.

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1. INSTALLATION (Cont'd.)

1.6. Connect each of the three wires from the control box toone of the three usable groups of wires in the conduit box.For an Electra-Gear motor, also connect each of the twowires from the thermostat to each of the two wires from thethermal switch. Properly close the cover on the conduit box.

WARNING! ONLY A QUALIFIED ELECTRICIANSHOULD PERFORM THIS WIRING. CAUTION MUSTBE TAKEN TO CAREFULLY READ AND UNDERSTANDTHE WIRING SCHEMATIC FOUND ON THE INSIDE OFTHE COVER OF THE CONDUIT BOX.

1.7. Disengage the locking dog. Depressing either theIN or OUT button on either the control box or the remotestation, test to make sure the winch drum turns in theappropriate direction; the rope must reel in from thebottom of the winch drum. Should the winch drum turnin the opposite direction than desired, open the conduit boxand disconnect two of the wires leading from the controlbox. Reverse the position of those two wires in respect totheir original position. Reconnect each of the two wires toeach of the bundle of wires from the winch motor. Closethe conduit box. The winch drum should now turn in theproper direction.

WARNING! TO REDUCE POTENTIAL OF ELECTRI-CAL SHOCK OR OTHER INJURY, TURN OFF ANDLOCK OUT OR TAG OUT POWER SOURCE BEFOREINITIATING ANY MAINTENANCE OR REPAIRS.

1.8. Coat all gear teeth with heavy-duty gear grease andlubricate both sprockets and the roller chain.

WARNING! FAILURE TO INSTALL THE VENT PLUG MAYRESULT IN DAMAGE TO THE GEARBOX.

1.9. The Vent Plug attached to the gearbox prior to shipmentmust be installed. Remove the Shipping Plug and discardproperly, replacing with the Vent Plug. The gearbox must bechecked to insure the gearbox is filled to the proper level withoil. Refer to the manufacturer's maintenance manual at-tached to the Vent Plug.

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2. ATTACHING THE WIRE ROPE

2.1. Rotate the drum until the cable clamp nuts appear in theslot on the side plate. Using a standard socket wrench withextension, loosen the nuts.

2.3. Slowly start to reel the rope onto the drum. Maintainenough tension on the rope to be sure the first coil beginssnugly against the side of the drum and each successivecoil is snug against the previous coil. Check to make surethe rope is reeled in from the bottom of the drum.

2.4. Continue to spool the rope until at least four (4)complete coils of wire rope are snugly on the drum.

WARNING! FOUR (4) COMPLETE COILS OF THEWIRE ROPE MUST BE ON THE DRUM AT ALL TIMESIN ORDER FOR THE WINCH TO ATTAIN ITS FULLHOLDING CAPACITY.

2.2. If installing a new winch, remove and discard the cableclamp spacer. If replacing worn out wire rope, remove therope from the cable clamp and dispose of the wire ropeproperly. Insert the new wire rope from the front of thewinch into the cable clamp until 3 to 4 inches of ropeextends through the clamp. Tighten the nuts evenly.

WARNING! PERIODICALLY RETIGHTEN THE NUTSON THE CABLE CLAMP TO INSURE CABLE IS SNUGAGAINST DRUM FLANGE.

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3. OPERATION OF WINCH

3.3. The electric brake is a disc type, normally set bymechanical spring pressure. It is released automaticallywhen electric power is supplied to its solenoid. In otherwords, brake release occurs simultaneously with the pow-ering of the motor and the brake locks automatically whenthe motor's electric power is turned off.

3.4. REEL-IN: Depress the IN/FORWARD push-button.Continue to reel in wire rope at rated load and speed untilmotor reaches stall. To stop the winch, release the IN/FORWARD button and the brake will engage.

WARNING! FAILURE TO STOP POWERING THEWINCH AFTER MOTOR REACHES STALL CAN RE-SULT IN MOTOR BURNOUT.

3.5. REEL-OUT: Check to see if the Locking Dog isengaged. If it is not, depress the OUT/REVERSE push-button. This will allow for the pay-out of the wire to thedesired length. To stop the winch, release the OUT/REVERSE button and the brake will engage. If the LockingDog is engaged, manually rotate the counterweight to-wards the back of the winch. Depress the IN/FORWARDpush-button until the counterweight rotates the locking dogout of engagement. Release the IN/FORWARD push-button and depress the OUT/REVERSE push-button.This will allow for the pay-out of the wire to the desiredlength. To stop the winch, release the OUT/REVERSEbutton and the brake will engage.

3.5.1. If the counterweight does not rotate the locking dogout of engagement the usual cause is that tension on thewire rope exceeds the stall pull of the winch. In this case,reposition the vessel to decrease the tension on the wirerope.

WARNING! FAILURE TO DISENGAGE THE LOCKINGDOG PRIOR TO REELING OUT CAN RESULT IN MO-TOR/WINCH FAILURE.

WARNING! KEEP ALL FINGERS, LOOSE CLOTHINGAND ANY FOREIGN OBJECTS AWAY FROM WINCHWHILE IN OPERATION.

3.6. Winches supplied with Electra-Gear motors will havea protective thermostat wound into the motor windings. Ifwired properly (refer to Section 1), the thermostat willprotect the motor from over heating. Should the motorreach the preset temperature, the thermostat will shutdown the motor causing the winch to stop operating. Waitseveral minutes to let the motor cool down before proceed-ing with winch operation.

3.1. The W. W. Patterson electric winch is designed foreasier operation and longer life. If sized correctly, installedproperly and maintained regularly, this winch will last manyyears.

3.2. The electric brake, electric motor and gearhead areintegrally mounted to the winch frame. Normally, a twobutton (IN/FORWARD and OUT/REVERSE) control sta-tion is used to operate the winch. Each button should bewired in such a way as to provide for automatic stoppingthe moment either button is released.

WARNING! ONLY A QUALIFIED ELECTRICIANSHOULD BE ALLOWED TO WIRE CONTROL BOXAND REMOTE STATION OF A WINCH.

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5. ELECTRIC BRAKE TROUBLE SHOOTING

WARNING! ONLY QUALIFIED PERSONNEL SHOULDBE ALLOWED TO INITIATE ANY MAINTENANCE ORREPAIRS.

WARNING! TO REDUCE POTENTIAL OF ELECTRI-CAL SHOCK OR OTHER INJURY, TURN OFF ANDLOCK OUT OR TAG POWER SOURCE BEFORE INITI-ATING ANY MAINTENANCE OR REPAIRS.

5.1. The electric brake is a disc type brake. The brake isset by mechanical spring pressure and is released auto-matically when power is supplied to its solenoid.

5.2. The brake has been factory wired, adjusted andtested prior to shipment.

5.3. Over time replacement of brake components may berequired. Common problems and their potential solutionsare as follows:

5.4. FAILURE TO STOP - If the brake does not stopproperly, it is usually due to friction disc or hub problems.

5.4.1. Check to see if friction discs are severly worn/broken and are in need of replacement

BRAKE LEADS

SOLENOID

PLUNGERPLUNGER GUIDE

BRAKE DISC

BRAKE HUB

BRAKE DISCDINGS BRAKE

5..4.2. Check to see if hub has shifted on shaft and is in needof alignment adjustment.

5.5. EXCESSIVE HUMMING - If excessive humming is heardcoming from the brake, it is usually due to plunger or coilproblems.

5.5.1. Clean dirt or foreign matter from between plunger,plunger guide and coil.

5.6 FAILURE TO RELEASE - If brake fails to release, it isusually due to wiring or coil failure.

5.6.1. Check to see if there is a broken lead.

5.6.2. Check the voltage coming into the brake. If the voltageis low, the plunger will not seat completely and could cause coilfailure.

5.6.3. Check for coil failure. If so, replace.

WARNING! FOR FURTHER INFORMATION, REFER TO THEELECTRIC BRAKE PARTS LIST AND SERVICE INSTRUC-TIONS INCLUDED ELSEWHERE IN THIS MANUAL.

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6. LUBRICATION AND INSPECTION

W. W. PATTERSON COMPANY3 Riversea Road, Pittsburgh, PA 15233 • Phone (800) 322-2018 • Fax (412) 322-2785

6.1. All grease fittings should be lubricated regularlyusing a POLYUREA grease such as ALTRA 500 EP2.

6.2. All gear teeth should be coated regularly with heavy-duty gear grease.

6.3. Regularly, inspect the winch carefully and com-pletely for worn gears and pawls, cracked welds and otherdamaged or worn parts. If any worn, cracked or damagedparts are found, stop use immediately and remove thewinch from service until all appropriate repairs are com-pletely performed.

6.4. Regularly, check roller chain tension. Correcttension is movement back and forth of the roller chain,when pushed and pulled by hand, between 3/4" and 1".Adjust top-plate bolts until correct tension is achieved.

6.5. Regularly, oil roller chain using brush or spout can.

PushPull

Correct Roller Chain Adjustment3/4" to 1" Movement

6.6 During the winter months if the winch runs slug-gishly the oil in the gear box could need changing. Allwinches are shipped from the factory with the gear boxfilled to 85% capacity with Mobile 600W Lube. Thefollowing table shows recommended lubricants and theiroperating ambient temperature range.

Lubricant Ambient Temp. RangeElectra M80 Lube +50 to +125Electra Lube +15 to +125Kendall-Three Star -10 to +100Mobil-Mobil 600W 32 to +100Mobil-Mobil SHC 629 -25 to +100Mobil-Mobil SHC 626 -40 to +40Conoco-Polar Start 600 -40 to +10Lubr. Eng.-Almasol 606 -10 to +40Mobil-Mobil SHC 624 -55 to 0Mobil-Mobilgear 627 -10 to +40Shell-Donax A.T.F. T-6 -55 to +5

Fleet Angle Distance

Fleet Angle

*Recommended Minimum Dis-tance from Drum to Sheave

Drum Dimensions for WWP65E-10-14Drum Diameter 14"Drum Width 14"Fleet Angle Distance* 22'

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